为了提升航空发动机的性能，气膜孔技术被广泛应用于涡轮叶片的冷却系统，但是由于涡轮叶片材料的难加工特性和扩散结构的复杂性，这种带有扩散结构的气膜孔高精度、高效率和表面无损伤加工成为工艺难题，仍然缺乏有效的加工手段。因此，本文提出了一种电火花电解复合方法与方形电极分块成形相集成的气膜孔加工工艺，方形电极分块成形方法用于快速去除扩散结构材料，复合电解加工过程用于去除重铸层和微裂纹缺陷。首先分析了电火花与电解复合加工的基本原理，分析总结了基体和重铸层不同组织的形成方式和电解特性，并提出了镍基单晶合金电火花电解复合加工的微观作用过程。在此基础上，提出了电火花电解复合工艺实现重铸层减薄的量化模型，将重铸层厚度的影响因素分为重铸层生成和去除两个步骤。为了实现对电火花电解复合工艺的精准调控，提出了电火花电解复合能场量化调控方法，通过将重铸层生成和去除两个因素分别与电火花和电解能量相对应，从而实现了对电火花电解复合加工过程的控制和预测。实验研究了多个参数对复合能场以及加工结果的影响，据此总结了实现无重铸层加工的条件。考虑重铸层厚度和加工精度两方面，提出了复合能场参数优化方法。针对气膜孔扩散结构的加工，采用方形电极分块成形加工，通过理论分析引起加工误差的因素，提出了电极误差补偿方法和轨迹误差伺服修正方法，提高了分块成形加工精度。在此基础上集成电火花电解复合加工方法，采用恒定加工速度进给策略，改善了分块成形加工中去除表面重铸层的工艺效果。

In order to improve the performance of aero-engines, the gas film hole technology is widely used in the cooling system of turbine blades. However, due to the difficult machining characteristics of turbine blade materials and the complexity of diffusion structure, the high precision, high efficiency and surface damage free processing of this kind of gas film hole with diffusion structure has become a technological problem, and there is still a lack of effective processing means. Therefore, this paper presents a gas film hole processing technology integrating the EDM electrolytic composite method with the square electrode block forming method. The square electrode block forming method is used to quickly remove the diffused structural materials, and the composite ECM process is used to remove the recast layer and micro-crack defects.Firstly, the basic principle of EDM and electrolytic composite machining is analyzed, the formation modes and electrolytic characteristics of different structures of matrix and recast layer are analyzed and summarized, and the micro-action process of EDM is proposed. On this basis, a quantitative model for the reduction of recast layer by electro-discharge machining (EDM) composite process is proposed. The influencing factors of recast layer thickness are divided into two steps: recast layer formation and recast layer removal.In order to achieve accurate control of EDM electrolytic composite process, a quantitative control method of EDM electrolytic composite energy field was proposed. By corresponding the two factors of formation and removal of recast layer to the EDM and electrolytic energy respectively, the control and prediction of EDM electrolytic composite process were realized. The effects of several parameters on the composite energy field and machining results were studied experimentally, and the conditions for non-recasting layer machining were summarized. Considering the thickness of recast layer and machining precision, the optimization method of composite energy field parameters was proposed.Based on the theory analysis of the factors causing the machining errors, the electrode error compensation method and the track error servo correction method are put forward to improve the machining precision of the block forming. On this basis, integrated EDM composite machining method and constant machining speed feeding strategy were adopted to improve the process effect of removing surface recast layer in block forming.